: M.

HEMANTH KUMAR

NAME

BRANCH :
ROLL NO
: 112N1A0133
YEAR & SEM : III 2
COLLAGE
: BRINDAVAN INSTITUTE OF
TECHNOLOGY & SCIENCE

MANUFACTURE OF STEEL PROCESS

INTRODUCTION ABOUT STEEL :
Steel is an alloy of iron, with carbon being the primary alloying element. The carbon content
quite soft, ductile, and weak. Carbon contents higher than those of steel make an alloy commonly of
steel is between 0.002% and 2.1% by weight. Too little carbon content leaves (pure) iron called pig
iron that is brittle and not malleable.
Additional elements may be present in steel: manganese, phosphorus, sulfur, silicon, and traces
of oxygen, nitrogen and aluminium.

STEEL PRODUCTION :
When iron is smelted from its ore by commercial processes, it contains more carbon than is
desirable. To become steel, it must be melted and reprocessed to reduce the carbon to the correct
amount, at which point other elements can be added. This liquid is then continuously cast into long slabs
or cast into ingots. Approximately 96% of steel is continuously cast, while only 4% is produced as ingots.
The ingots are then heated in a soaking pit and hot rolled into slabs, blooms, or billets. Slabs are hot or
cold rolled into sheet metal or plates. Billets are hot or cold rolled into bars, rods, and wire. Blooms are hot
or cold rolled into structural steel, such as I-beams and rails. In modern steel mills these processes often
occur in one assembly line, with ore coming in and finished steel coming out. Sometimes after a steel's
final rolling it is heat treated for strength, however this is relatively rare.

MODERN STEEL MAKING :

Since the 17th century the first step in European steel production has been the smelting of iron ore into pig
iron in a blast furnace.Originally using charcoal, modern methods use coke, which has proven more
economical

Created by M.HEMANTH KUMAR

Created by M.HEMANTH KUMAR

MANUFACTURE OF STEEL :

The figure shows a flowchart of the integrated manufacturing process for iron and steel using the blast furnace and
basic oxygen furnace (denoted BF and BOF hereinafter, respectively), which is presently the most commonly used
method (51% of world steel production). After the BF-BOF process, molten steel is controlled to a target
composition and temperature and is then cast by continuous casting machine to produce slabs, blooms, and billets.
These castings are rolled to the required dimensions by the rolling mill to produce steel products. The smelting and
refining process for iron and steel in the BF-BOF process involves the carbon reduction of iron ore (Fe2O3) in the
BF to make molten iron, and decarburization of molten iron in the BOF to make molten steel.
Major reducing agent in the BF is the carbon monoxide gas(CO) generated by the oxidation of the carbon(C) in
coke. Consequently, carburization takes place at the same time as reduction, producing hot metal(molten iron)
containing about 4% carbon. The hot metal is decarburized to the required carbon content in the BOF. The main
reaction in this process is the oxidization of the carbon in the hot metal by both pure oxygen gas (O2) and iron oxide
(Fe2O3). The residual oxygen, after contributing to this decarburization reaction, remains in the molten steel. This
oxygen is fixed and removed by deoxidation reagents such as silicon and aluminum as SiO2 and Al2O3 or is
removed as carbon monoxide gas in the subsequent vacuum degassing process.
In addition to the BF-BOF process, there is another process which utilizes mainly scrap as an iron source, with
some direct reduced iron whenever necessary. The direct reduced iron is produced by reducing iron ore with
reformed natural gas, whose principal components are hydrogen, carbon monoxide, and methane. The scrap, along
with direct reduced iron, is then melted in an electric arc furnace (denoted EAF hereinafter) to produce molten steel
which is subsequently processed by the continuous casting machine, as mentioned above.
The molten steel from the BOF and EAF is then deoxidized and alloying elements are added in the prescribed
amounts. The molten steel is then held at the target temperature and continuously cast, and the castings obtained are
cut to the prescribed length. After heating to the rolling temperature in a reheating furnace, these castings are hotworked to the required products. Steel shapes, bars, and wire rods are worked on section and bar mills and wire-rod
mills equipped with caliber rolls, plates are worked on reversing mills, and hot-rolled steel sheets are worked on hot
strip mills. After pickling to remove scale from the surface, the hot-rolled steel sheets are worked to cold-rolled
steel sheets on reversing mills or tandem rolling mills, and the cold-rolled steel sheets are tinned or galvanized as

Created by M.HEMANTH KUMAR

required to produce various surface-treated steel sheet products. Steel pipe is produced by forming and welding
steel sheets or plates, or by piercing a billet and rolling to the final dimensions without a seam.

The production process for the sponge iron is as given below:

Coal Raw Material Handling Yard
Coal received from Coal mines/Port is stored in a Coal Shed. From the Coal shed the coal is fed
into the day bins for feeding to the crushing & screening Plant.
Iron Ore Yard
Iron Ore received from the mines is stored in the yard. From the storage yard material is fed into
the day bins for feeding the crushing & screening plant.
Coal Crushing & Screening plant
Coal is crushed & Screened to required fractions below 20mm size and conveyed to the stock
house bins. The over size is recycled back and crushed to the required size.
Iron Ore Crushing & Screening Plant
Iron Ore is crushed & Screened to required fractions i.e. -18mm to +4mm. The required sizes are
fed into the stock house bins. The rejected size i.e. -4mm is conveyed to the reject bin from where
it is disposed off. The oversize of +18mm is recycled back and crushed to the required size.
Lime Stone
Lime Stone of size 0-8mm are conveyed from the storage yard to the stock house bins.
Stock House
Stock House consists of 8 bins of which 3 are Injection Coal, 3 are Feed Coal, 1 is Iron Ore and
balance is Lime stone bin. From the Stock House Two Conveyors are installed for conveying
Injection Coal and other conveyor conveys Iron Ore, Feed Coal and Lime Stone. Below the stock
house weighfeeders are installed from which the raw materials are fed into the kiln in required
quantities.
Kiln
From the Stock House from one end of the Kiln Injection Coal is fed into the Kiln and from the
other end Iron Ore, Feed Coal and Lime stone is fed. The Kiln is fired with the injection coal from

Created by M.HEMANTH KUMAR

the discharge end and a constant temperature of 1000 Deg. C is maintained inside the kiln. The
Kiln is rotated in certain RPM. The Iron Ore in the Kiln is reduced to Sponge Iron. The Sponge Iron
comes out through discharge end through a discharge chute and enters the cooler.
After Burning Chamber
The combustibles in the waste gases generated from the Sponge Iron Process are subjected to
total combustion in the After Burning Chamber. From the ABC the gases are sent to the Gas
Conditioning Tower.
Gas Conditioning Tower (GCT)
The Gases from the ABC are sent to the GCT. The gases at 900 to 1000 Deg. C are fed to the Gas
Conditioning Tower. In the GCT the gases are cooled by spraying water. The gases are cooled to
about 200 Deg. C. The gases are then sent to Electro Static Precipitator.
Electro Static Precipitator (ESP)
The gases sent to the ESP contain dust particles and gases. In the ESP the gases are made free of
dust particles and sent to a chimney for letting it into the open air. The dust particles in the gases
are collected in the ESP and this fly ash is collected by a chain conveyor below the ESP which is
inturn transmits it in to a Surge Bin.
Cooler
The Sponge Iron received from the Kiln is cooled in the cooler. Water is sprayed on the cooler for
cooling the sponge iron. The Sponge Iron is then conveyed to an Intermediate Bin or Product
Separation System.
Intermediate Bin
The Sponge Iron discharged from the cooler can be either stored in the Intermediate Bin or
directly conveyed to Product Separation House. During any shutdown in the Product Separation
House the material is stored in the Intermediate Bin for reconveying the same to Product
Separation System when it is ready.
Product Separation House
The Product separation house contains a Vibrating Screen and two Magnetic Separator. The
Sponge Iron is screened to size fractions of +4mm to 25 mm (Sponge Iron Lumps) and -4mm
(Sponge Iron Fines) and is sent to the Magnetic Separators. In the Magnetic Separators the
Sponge iron lumps & Fines is separated from the Non Magnetic material i.e. Char. The Sponge

Created by M.HEMANTH KUMAR

Iron Lumps and fines are then stored in the Product Storage Bin and the non magnetic material,
char, is collected in char storage bin.
Product Storage Bins
The product i.e. Sponge Iron Lumps and fines are stored in these bins from where they are
dispatched to the customers.
Char Storage Bin
The non magnetic material, char, is collected in the char bin and then loaded in to the dispatch
trucks.

Created by M.HEMANTH KUMAR